Wall Element for the Construction of a Housing

Abstract

The present disclosure relates to a wall element (10) for the construction of a housing to accommodate an energy storage device or to create a cooling plate, comprising a base plate (2) and a flow channel (4) formed in the base plate (2) with a flow cross-section for a cooling medium (6) to flow through, an inlay (8) being disposed in the flow channel (4) in order to reduce the flow cross-section.

Claims

1-15. (canceled)

16. A wall element for construction of a housing comprising: a base plate; and a flow channel formed in the base plate with a flow cross-section for a cooling medium to flow through, wherein an inlay disposed in the flow channel in order to reduce the flow cross-section.

17. The wall element according to claim 16, wherein the inlay comprises turbulators to generate turbulence in the cooling medium.

18. The wall element according to claim 17, wherein the turbulators are designed in such a way that a pressure drop generated by the turbulators in the cooling medium flowing through the flow channel is less than 10% compared to the pressure drop that occurs when cooling medium flows through the flow channel at the same volumetric flow rate without turbulators.

19. The wall element according to claim 17, wherein the turbulators are formed in one piece with the inlay.

20. The wall element according to claim 16, wherein the inlay comprises turbulators to generate turbulence in the cooling medium, the turbulators comprising continuous structures in a form of wires, cylinders or surface roughnesses.

21. The wall element according to claim 16, wherein the inlay comprises at least one flow passage element to deflect the cooling medium.

22. The wall element according to claim 21, wherein the inlay together with the at least one flow passage element subdivides the flow channel into at least a first subchannel and a second subchannel, such that, when cooling medium flows through the flow channel, the cooling medium flows from the first subchannel into the second subchannel.

23. The wall element according to claim 16, wherein the inlay comprises a flow passage element which is adapted to produce a deflection of the cooling medium within at least one subchannel, such that a main flow path of the cooling medium formed upon flowing through is longer than a length of the subchannel concerned.

24. The wall element according to claim 16, wherein the base plate comprises two parallel subplates spaced from each other, and the flow channel extends between the subplates.

25. The wall element according to claim 16, wherein the base plate further comprises an inlet and an outlet, the inlet or the outlet being disposed orthogonally to a surface of the base plate.

26. The wall element according to claim 25, wherein the inlet or the outlet inside the base plate open into an inlet channel and an outlet channel respectively, the inlet channel or the outlet channel being formed at least partially by the inlay.

27. The wall element according to claim 16, wherein the inlay forms cavities in the flow channel through which cooling medium does not flow.

28. The wall element according to claim 16, wherein the inlay comprises at least one subdivision which, together with the base plate, forms a separate flow channel in the flow channel, the subdivision preferably being formed in one piece with the inlay.

29. The wall element according to claim 16, wherein the base plate is formed as an extruded part, preferably as an aluminum extruded part.

30. The wall element according to claim 16, wherein the inlay comprises a plastic and is preferably configured to be thermally insulating.

31. A method of manufacturing a wall element comprising: manufacturing a base plate by an extrusion process, the base plate including a flow channel having a flow cross-section for a cooling medium to flow through; and inserting an inlay into the flow channel to reduce the flow cross-section of the flow channel.

32. A wall structure comprising a plurality of wall elements, wherein one or more of the plurality of wall elements comprises: a base plate; and a flow channel formed in the base plate with a flow cross-section for a cooling medium to flow through, wherein an inlay disposed in the flow channel in order to reduce the flow cross-section.

33. The wall structure according to claim 32, wherein the inlay comprises turbulators to generate turbulence in the cooling medium.

34. The wall structure according to claim 33, wherein the turbulators are designed in such a way that a pressure drop generated by the turbulators in the cooling medium flowing through the flow channel is less than 10% compared to the pressure drop that occurs when cooling medium flows through the flow channel at the same volumetric flow rate without turbulators.

35. The wall structure according to claim 33, wherein the turbulators are formed in one piece with the inlay.

Description

BRIEF DESCRIPTION OF FIGURES

[0047] Further embodiments of the disclosure are explained in more detail by the following description of the figures. These show:

[0048] FIG. 1 A wall element according to the state of the art in a perspective view

[0049] FIG. 2 A side view of a wall element according to a first embodiment

[0050] FIG. 3 A side view of a wall element according to a further embodiment

[0051] FIG. 4 A side view of a wall element according to a further embodiment

[0052] FIG. 5 A side view of a wall element according to a further embodiment

[0053] FIG. 6 A side view of a wall element according to a further embodiment

[0054] FIG. 7 A side view of a wall element according to a further embodiment

[0055] FIG. 8 A side view of a wall element according to a further embodiment

[0056] FIG. 9 A plan view of an inlay according to a further embodiment and

[0057] FIG. 10 A plan view of a wall element showing an inlay according to the embodiment shown in FIG. 9 together with the base plate.

DETAILED DESCRIPTION

[0058] Certain embodiments are described below on the basis of the figures. Identical, similar or similarly acting elements are given identical reference signs in the various figures, and a repeated description of these elements is in some cases omitted in order to avoid redundancies.

[0059] FIG. 1 schematically illustrates a wall element 10 for the construction of a housing to accommodate an energy storage device in a perspective view.

[0060] The wall element 10 is suitable for cooling an energy storage device, not shown, by means of a cooling medium, not shown. The wall element 10 comprises a base plate 2 and a flow channel 4 formed within the base plate 2 for the cooling medium 6 to flow through. More specifically, the flow channel 4 is formed between a first subplate 2A and a second subplate 2B of the base plate 2.

[0061] The base plate 2 can be manufactured by extrusion.

[0062] The flow channel 4 within the base plate 2 has a comparatively large flow cross-section due to the manufacturing method. As a result, dead water areas may be formed in the flow channel 4 and, for a given cooling medium flow, the flow velocity is relatively low, thereby reducing the cooling efficiency. This efficiency is to be improved by the embodiments described below.

[0063] FIG. 2 is a side view of a wall element 10 according to a first embodiment. This shows an end face of the wall element 10.

[0064] The wall element 10 is suitable for cooling an energy storage device, not shown, by means of a cooling medium 6 and comprises a base plate 2. A flow channel with a flow cross-section is formed within the base plate 2 for a cooling medium 6 to flow through. In the illustration shown in FIG. 2, the flow channel 4 extends into the plane of the drawing.

[0065] An inlay 8 is disposed in the flow channel 4 to reduce the flow cross-section.

[0066] The flow cross-section of the flow channel 4 is reduced via the volume displacement by the inlay 8, which is apparent in the cross-sectional view from the reduced height of the flow cross-section. In the illustrated embodiment, the inlay 8 lies against an inner surface of the base plate 2 and the flow channel 4 is formed between the first subplate 2A of the base plate 2 and the inlay 8.

[0067] The inlay 8 is inserted into the flow channel 4 of the base plate 2 along the flow channel 4. The volume displacement of the inlay 8 eliminates dead water areas and also reduces the flow cross-section, thus improving the flow of the cooling medium 6 in the flow channel 4 and increasing the flow velocity for a given volumetric flow rate.

[0068] The inlay 8 may be formed from a plastic material, for example as an injection-molded or deep-drawn part. The base plate 2 may be formed from a metallic material, for example as an extruded part.

[0069] By using a metallic material for the base plate 2, good heat conduction can be achieved between the energy storage device or the components to be cooled disposed on the base plate 2 and the cooling medium 6 carried in the flow channel 4, so that efficient cooling can be achieved.

[0070] The inlay 8 formed as a plastic part, on the other hand, may be formed as an insulator. Accordingly, the presence of the inlay 8 thermally insulates the wall member 10 from the outside, that is to say, the subplate 2B is cooled less. This improves cooling performance on the inner side of the base plate 2 and increases thermal efficiency.

[0071] In the embodiment shown in FIG. 2, the end faces of the base plate 2 are not yet closed. These openings are closed by positive substance jointing, form fitting or force fitting, for example by means of welding and/or gluing and/or screwing and/or by means of a riveted joint in a process step that follows the insertion of the inlay 8 into the flow channel 4.

[0072] FIG. 3 discloses a side view of a wall element 10 according to a further embodiment. Like the embodiment disclosed in FIG. 2, the wall element 10 of the present embodiment is suitable for cooling an energy storage device, not shown, by means of a cooling medium 6 and comprises a base plate 2. The wall element further comprises a flow channel 4 formed within the base plate 2 for a cooling medium 6 to flow through. An inlay 8 is disposed in the flow channel 4 to reduce the flow cross-section.

[0073] The flow cross-section in the flow channel 4 is reduced via the volume displacement of the inlay 8, which is apparent from the reduced height of the flow cross-section. Furthermore, the inlay 8 has turbulators 12 to generate turbulence in the cooling medium 6. In the embodiment shown in FIG. 3, the turbulators 12 have projections that extend part way into the flow channel 4.

[0074] The inlay 8 is inserted into the flow channel 4 of the base plate 2. The turbulators 12 are formed in one piece with the inlay 8. Consequently, no further parts may be required. This also means that turbulators 12 can have any geometry. The turbulators 12 influence the flow in the flow channel 4.

[0075] The volume displacement of the inlay 8 eliminates dead water areas and improves the flow in the flow channel 4. Moreover, the presence of the inlay 8 thermally insulates the wall member 10 from the outside, that is to say, the subplate 2B is cooled less. This improves cooling performance and increases thermal efficiency. The turbulators 12 can furthermore cause the cooling medium to swirl as it flows through the flow channel 4, as a result of which the cooling performance is applied more effectively to the base plate, thus further increasing thermal efficiency.

[0076] In the embodiment shown in FIG. 3, the sides of the base plate 2 are not yet closed. These openings are closed by welding and/or gluing in a process step that follows the insertion of the inlay 8 into the flow channel 4.

[0077] FIG. 4 discloses a side view of a wall element 10, but in a modified embodiment. Like the embodiment disclosed in FIG. 2 and FIG. 3, the wall element 10 of the present embodiment is also suitable for cooling an energy storage device, not shown, by means of a cooling medium 6 and comprises a base plate 2. The wall element 10 according to the embodiment of FIG. 4 likewise comprises a flow channel 4 formed within the base plate 2 for a cooling medium 6 to flow through. An inlay 8 is likewise disposed in the flow channel 4 to reduce the flow cross-section.

[0078] The inlay 8 has subdivisions 13 that are directly integrated into the inlay 8 and that divide the remaining space of the flow channel 4 into individual flow channels. The flow channels created in this way can run parallel to each other. Through the dimensioning of the flow channels created in this way, the overall effective flow cross-section can be adjusted and the flow velocity thereby adapted to the respective application.

[0079] In other words, the embodiment illustrated in FIG. 4 differs from the embodiment illustrated in FIG. 3 in that the inlay 8 has subdivisions 13 with continuous structures which together extend as far as the opposite subplate 2A. The turbulators 12 of FIG. 3, on the other hand, do not extend continuously to the opposite subplate 2A, but still allow cooling medium to pass through. Furthermore, the turbulators 12 are not necessarily formed continuously along the length of the flow channel 4. The subdivisions 13, on the other hand, when configured to form flow channels, extend along the entire length of the flow channel 4. This allows individual flow channels to be formed, which can be designed in accordance with the desired or required cooling capacity in predefined areas of the wall element 10 and can, for example, have a winding or meandering structure.

[0080] Moreover, the presence of the inlay 8 thermally insulates the wall member 10 from the outside, that is to say, the subplate 2B is cooled less. This improves cooling performance and increases thermal efficiency. In the embodiment shown in FIG. 4, the sides of the base plate 2 are not yet closed. These openings are closed by welding and/or gluing in a process step that follows the insertion of the inlay 8 into the flow channel 4.

[0081] Alternatively or additionally, in an embodiment not shown, the turbulators 12 or subdivisions 13 may have indentations. However, the turbulators 12 or subdivisions 13 may have other continuous structures, in particular wires, cylinders and/or surface roughnesses.

[0082] In particular, the turbulators 12 or subdivisions 13 shown in FIG. 3 and/or FIG. 4 can be specifically designed so that the pressure drop generated in the cooling medium 6 flowing through the flow channel 4 is less than 10%, less than 1%, compared to the pressure drop that occurs when cooling medium 6 flows through the flow channel 4 at the same volumetric flow rate without turbulators 12 or subdivisions 13.

[0083] The embodiments disclosed in FIGS. 2, 3 and 4 have in common that the inlay 8 lies against the subplate 2B. However, the inlay 8 can also lie against the opposite subplate 2A. The said embodiments also have in common that the inlay 8 can be inserted laterally between the two subplates 2A and 2B of the base plate 2 of the wall element 10.

[0084] FIG. 5 discloses a side view of a further embodiment of the wall element 10. According to this embodiment, the base plate 2 again has a flow channel 4 extending into the plane of the drawing, in which an inlay 8 is again introduced. In this embodiment, the inlay 8 divides the flow channel 4 into two subchannels 4A and 4B disposed one above the other, which are fluidly connected to each other via a flow passage element 14 in the form of a recess in the inlay 8. In other words, the cooling medium 6 is able to flow from the first subchannel 4A into the second subchannel 4B via the flow passage element 14.

[0085] The cooling medium 6 flows into the flow channel 4 of the base plate 2 via an inlet 16 at an inlet temperature T.sub.E. The initially cold cooling medium 6 then flows along the inlay 8 through the upper subchannel 4A of the flow channel 4, heating up as a result of heat transfer processes and being deflected at the flow passage element 14 into the lower subchannel 4B. The cooling medium 6 then flows in the lower subchannel 4B, in counterflow to the cooling medium 6 flowing in the upper subchannel 4B, to an outlet 18 and ultimately out of the flow channel 4. The wall element 10 and, in particular, the flow passage element 14 are dimensioned such that the cooling medium 6 achieves a desired flow velocity at a predefined volumetric flow rate in order to enable efficient and homogeneous heat transfer.

[0086] At the end of the subchannel 4B, the cooling medium 6 has reached an outlet temperature T.sub.A. The inlet 16 and the outlet 18 are designed as separate channels.

[0087] If the wall element 10 is used as part of a housing to accommodate an energy storage device, part of the heat transferred by the cooling medium 6 can already be dissipated to the environment on the respective outer side of the housing—for example, on the side where the subchannel 4B is disposed.

[0088] With this embodiment, it may be possible to dispense with an external heat exchanger altogether. The heat transfer processes in the interior and to the environment can be optimized in the subchannels 4A and 4B by optimizing the geometry of the cooling channels and ensuring a suitable flow velocity (via a built-in pump). A closed circuit is therefore defined in the cooling plate described.

[0089] In a variant of this embodiment, the capillary action of so-called “heat pipes” can also be used to circulate the coolant, so that the pump can also be dispensed with.

[0090] In a further variant of this embodiment, circulation of the coolant or refrigerant is effected by evaporation on the inner, hot side and re-condensation on the outer, cold side (known as evaporative cooling). Natural convection of coolant in the heat exchanger can be realized in this way.

[0091] The inlay 8 is inserted into the flow channel 4 of the base plate 2. The flow passage elements 14 are directly integrated into the inlay 8. This eliminates the need for additional parts, facilitating assembly due to the small number of parts and keeping costs down. This also means that flow passage elements 14 can have any geometry.

[0092] FIG. 6 discloses a further side view of a further embodiment of the wall element 10. According to this embodiment, the base plate 2 has an inlay 8. The inlay 8 has flow passage elements 14 in the form of recesses to deflect the cooling medium 6.

[0093] The flow passage elements 14 of the inlay 8 are designed such that the flow channel 4 is divided into two fluidly connected subchannels 4A and 4B, such that, when cooling medium 6 flows through the fluid channel 4, the cooling medium 6 flows from the first subchannel 4A into the second subchannel 4B.

[0094] The cooling medium 6 flows into the flow channel 4 of the base plate 2 via an inlet 16 at an inlet temperature T.sub.E. The initially cold cooling medium 6 flows further along the inlay 8 through the flow channel 4 and heats up due to heat transfer processes. The flow passage elements 14 are configured such that the cooling medium 6 reaches an outlet temperature T.sub.A at the end of the flow channel 4. At the end of the flow channel 4, the cooling medium 6 is deflected via the flow passage element 14 and flows back in counterflow to the cold cooling medium 6. The flow-back in counterflow takes place in parallel.

[0095] The embodiment shown in FIG. 6 differs from the embodiment disclosed in FIG. 5 in that the inlet 16 and the outlet 18 are designed as a common opening disposed on one side of the base plate 2. Consequently, the cooling medium 6 is fed into or discharged laterally from the base plate 2 of the wall element 10.

[0096] The inlay 8 is again inserted into the flow channel 4. The flow passage elements 14 are directly integrated into the inlay 8. This eliminates the need for additional parts, facilitating assembly due to the small number of parts and keeping costs down. This also means that flow passage elements 14 can have any geometry. The flow passage elements 14 influence the flow in the flow channel 4.

[0097] FIG. 7 discloses a side view of a further embodiment of the wall element 10. According to this embodiment, the base plate 2 has an inlay 8. The inlay 8 has a flow passage element 14 to deflect the cooling medium 6.

[0098] The cooling medium 6 flows into the flow channel 4 of the base plate 2 via an inlet 16 at an inlet temperature T.sub.E. The initially cold cooling medium 6 flows further along the inlay 8 through the flow channel 4 and heats up due to heat transfer processes. At the end of the flow channel 4, the cooling medium 6 is deflected via the flow passage element 14 and flows, in counterflow to the cold cooling medium 6, to and finally out of the outlet 18. The inlet 16 and the outlet 18 are disposed orthogonally to the surface of the base plate 2. The inlet 16 and the outlet 18 are designed as separate channels. The flow passage element 14 is configured such that the cooling medium 6 reaches an outlet temperature T.sub.A at the end of the flow channel 4B.

[0099] The embodiment disclosed in FIG. 7 is identical to the embodiment disclosed in FIG. 5, except for the design of the flow passage element 14. In the embodiment discussed here, the flow passage element 14 is configured to create a deflection of the cooling medium 6 in both subchannels 4A and 4B, such that a main flow path (shown as arrows) formed when cooling medium 6 flows through the subchannels is longer than the length of the respective subchannel 4A and 4B.

[0100] FIG. 8 shows a side view of a wall element 10 according to a further embodiment. According to this embodiment, the base plate 2 has an inlay 8 that divides the base plate 2 into two fluidly separate areas, namely a flow channel 4 and a cavity 24.

[0101] The cooling medium 6 flows into the flow channel 4 of the base plate 2 via an inlet 16 at an inlet temperature T.sub.E. The initially cold cooling medium 6 flows further along the inlay 8 through the flow channel 4 and heats up due to heat transfer processes. At the end of the flow channel 4, the cooling medium 6 reaches an outlet temperature T.sub.A and is discharged at an outlet temperature T.sub.A from the outlet 18. The inlet 16 and the outlet 16 are configured as separate channels disposed on either side of the base plate 2.

[0102] The inlay 8 accordingly reduces the cross-section of the flow channel 4 in the base plate 2, so that a predefined flow velocity of the cooling medium 6 in the flow channel 4 can be achieved at a predefined volumetric flow rate. Furthermore, the base plate 2 can be thermally insulated from the outside by means of the cavity 24.

[0103] FIG. 9 discloses a plan view of an inlay 8 according to another embodiment of the inlay 8. The inlay 8 has turbulators 12 to generate turbulence in the cooling medium, the turbulators 12 being designed as projections. In this case, the turbulators 12 are formed as, for example, oval projections, whereby the pressure drop generated in the cooling medium when flowing through the flow channel 4 is less than 10%, in particular less than 1%, compared to the pressure drop that would occur when cooling medium flows through the flow channel 4 at the same volumetric flow rate without turbulators. In a further embodiment, not shown, the turbulators are formed as recesses and/or bulges.

[0104] The inlay 8 according to the embodiment disclosed in FIG. 9 furthermore has a flow passage element 14 to deflect the cooling medium. This can ensure a pressure-drop-optimized intake of cooling medium.

[0105] Furthermore, the inlet 16 and the outlet 18 inside the base plate 2 open into an inlet channel 20 and an outlet channel 22 respectively. In this case, the inlet channel 20 and the outlet channel 22 are partially formed by the inlay 8.

[0106] FIG. 10 is a plan view of a wall element 10. FIG. 10 shows an inlay 8 according to the embodiment shown in FIG. 9 together with the base plate 2. The base plate 2 of the wall element 10 has an essentially rectangular footprint. Furthermore, the base plate 2 has fastening means 28 on an outer side 26. The base plate 2 may be manufactured by an extrusion process, in particular by an aluminum extrusion process. The inlay 8 of the wall element 10 may be made of or comprise a plastic.

[0107] To manufacture a wall element according to the wall element 10 shown in FIG. 10, in a first step the base plate 2 is manufactured by an extrusion process and in a second step the inlay 8 is inserted into the base plate 2. In a third step, the remaining openings are sealed, in particular by welding and/or gluing.

[0108] Insofar as applicable, all of the individual features shown in the embodiments may be combined and/or interchanged without departing from the scope of the disclosure.

LIST OF REFERENCES

[0109] T.sub.A Outlet temperature

[0110] T.sub.E Inlet temperature

[0111] 2 Base plate

[0112] 2A, 2B Subplate

[0113] 4 Flow channel

[0114] 4A, 4B Subchannel

[0115] 6 Cooling medium

[0116] 8 Inlay

[0117] 10 Wall element

[0118] 12 Turbulator

[0119] 13 Subdivision

[0120] 14 Flow passage element

[0121] 16 Inlet

[0122] 18 Outlet

[0123] 20 Inlet channel

[0124] 22 Outlet channel

[0125] 24 Cavity

[0126] 26 Outside

[0127] 28 Fastening means